Continuous constant tension air covering
An air covered yarn is formed by feeding multiple polymeric yarns along a predetermined path to an air jet. Before reaching the air jet, the polymeric yarn ends are textured to form covering yarns. An elastomeric core is also fed along a predetermined path to the air jet. The covering yarn and elastomeric core are then pneumatically entangled to form a composite yarn.
1 . A method for forming an air covered yarn, comprising:
(a) feeding polymeric inelastic yarns along a predetermined path;
(b) texturing the polymeric yarns to form a covering yarn;
(c) feeding an untextured elastomeric yarn along a predetermined path at a substantially constant tension, wherein the constant tension is maintained by an electronic tension controller;
(d) feeding the covering yarn and the elastomeric yarn through the air jet; and
(e) pneumatically entangling the elastomeric core and the covering yarn to produce an entangled composite yarn.
2 . The method of claim 1 wherein the elastomeric yarn is selected from the group consisting of spandex, elastane, rubber, polyetheresters, elastoesters, and elasterell P.
3 . The method of claim 1 wherein the elastomeric yarn is continuously fed from a plurality of supply packages, the supply packages being spliced together.
4 . The method of claim 1 wherein texturing the polymeric yarns comprises:
(a) drawing the polymeric yarns through a heating zone;
(b) cooling the polymeric yarns; and
(c) feeding the polymeric yarns through a false twist unit, wherein the yarns are crimped.
5 . The method of claim 4 wherein the covering yarn and the elastomeric yarn are fed through the air jet when the crimp in the textured covering yarn is maximized.
6 . The method of claim 4 wherein the polymeric yarn ends are stretched when drawn through the heating zone.
7 . A method for forming an air covered yarn, comprising:
(a) feeding polymeric inelastic yarns along a predetermined path;
(b) texturing the polymeric yarns to form a covering yarn;
(c) feeding an untextured elastomeric yarn along a predetermined path at a predetermined tension, wherein the elastomeric yarn is continuously fed from a plurality of supply packages, the supply packages being spliced together;
(d) feeding the covering yarn and the elastomeric yarn through the air jet; and
(e) pneumatically entangling the elastomeric core and the covering yarn to produce an entangled composite yarn.
8 . The method of claim 7 wherein a substantially constant tension is maintained in the elastomeric core yarn by an electronic tension controller while the elastomeric core is being fed along the path to the air jet.
9 . The method of claim 7 wherein the elastomeric yarn is selected from the group consisting of spandex, elastane, rubber, polyetheresters, elastoesters, and elasterell P.
10 . The method of claim 7 wherein texturing the polymeric yarns comprises:
(a) drawing the polymeric yarns through a heating zone;
(b) cooling the polymeric yarns; and
(c) feeding the polymeric yarns through a false twist unit, wherein the yarns are crimped.
11 . The method of claim 10 wherein the covering yarn and the elastomeric yarn are fed through the air jet when the crimp in the textured covering yarn is maximized.
12 . The method of claim 10 wherein the polymeric yarn ends are stretched when drawn through the heating zone.
13 . An apparatus for forming an air covered yarn and having a heating zone, a cooling zone, and a false twist texturizer for forming an inelastic covering yarn, further comprising:
(a) a creel rack for a plurality of supply packages of elastomeric core material;
(b) an electronic tension controller for controlling the tension in the elastomeric core; and
(c) an air jet for entangling the covering yarn and the elastomeric core to form a composite air covered yarn.
14 . The apparatus of claim 13 wherein the creel rack is mounted on the apparatus.
15 . The apparatus of claim 13 wherein the creel rack comprises a plurality of creels positioned on substantially the same level.
16 . The apparatus of claim 15 wherein each of the plurality of creels are angled inwardly toward the electronic tension controller.
17 . The apparatus of claim 13 where the size of the air covered yarn is not limited by the size of the supply packages of elastomeric core material.